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Chemical

Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.

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Petrochemical

Petrochemical companies’ needs are extremely diverse. To come out ahead in today’s highly competitive marketplace, producers are striving to improve quality and productivity. Yokogawa provides tailor-made solutions for these needs based on its long and wide-ranging experience in this field.

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Base Chemical

Yokogawa has been serving the bulk chemical market globally and is the recognized leader in this market. With products, solutions, and industry expertise, Yokogawa understands your market and production needs and will work with you to provide a reliable, and cost effective solution through the lifecycle of your plant.

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Specialty & Fine Chemical

Yokogawa has long served customers in the specialty and fi ne chemicals market. With a market leading batch solution that offers the best in class reliability and flexibility as well as industry experts who understand the complex requirements in designing a batch solution, you can be assured that in your partnership with Yokogawa you will have a system that will enable you to produce products that meet your customers’ needs in the future while maintaining safety and regulatory compliance.

Biofuel thumbnail

Biofuel

To combat global warming, the production and consumption of biofuels is on the rise around the world. As a leading provider of measurement and control solutions to the chemical, oil, and other industries, Yokogawa has developed technologies that can be used to ensure the reliable and efficient production of bioethanol and other types of renewable fuels.

Chemical Industry Value Chain

Yokogawa Electric Corporation released the world’s first DCS in 1975, which rapidly became popular among many customers in the chemical industry worldwide. Yokogawa has thus been contributing to the safe and stable operation of users’ plants as a leading supplier of process control solutions in this industry.
As the processes, products and value chain of the chemical industry are becoming more complex and sophisticated, so too are customer requirements. Yokogawa continues to provide industrial solutions and services to meet those needs by leveraging its wealth of experience and expertise in this field. We have also released various new solutions such as energy management in order to optimize plant operation.
Yokogawa will continue to meet the expectations of customers in the chemical industry by providing state-of-the-art automation solutions as a comprehensive supplier.

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Production Excellence

Production Management

  • MES integration
    A variety of individual systems that perform scheduling and other functions are included in the manufacturing execution systems (MES) domain. The connectivity among systems is a fundamental key enabler for agile production management.
  • Workflow standardization
    Production workflows should be defined and monitored for reliable production management. The standardization of workflows is especially effective at companies with multiple production sites. 
  • Real-time production management
    Overall real-time production management is required to speed up the production plan-do-check-action (PDCA) cycle.

    
Production Control

  • Loop tuning
    Process identification (PID) control plays a fundamental role in process control. Proper tuning is required for stable process control and is a prerequisite for advanced-level control. 
  • Advanced automation
    Advanced process control and knowledge-based navigation systems are key contributors to a well-automated operation.  
  • Real-time optimization
    Plant-wide optimization can be achieved with a real-time optimizer using rigorous model calculations.

    
Production Monitoring

  • Alarm rationalization
    An approach to alarm management based on the well-known engineering equipment & materials users’ association (EEMUA) No.191 guideline is recommended. Alarm root cause analysis is also an effective approach to successful alarm rationalization.  
  • KPI monitoring
    A wide variety of key performance indicators (KPI) should be monitored by each person. KPI monitoring requires comparison with targets and drilling down for detailed information.    
  • Production navigation
    Production tasks need to be managed correctly by the system. Task progress monitoring is a valuable bridge between planning and manufacturing that facilitates cooperation in production management.

    
Production Environment

  • Operator training
    Operator training systems allow operators to gain experience in handling various situations such as equipment malfunctions and in performing start-ups and other routine operations. It helps operators upgrade their skills.    
  • Control room design
    Control room design needs to take into consideration all aspects of the work environment including ergonomics, safety, ease of communication, functionality, automation of systems, and business policy.    
  • Resource optimization
    A central control room is desirable for an effective production environment. All production-related units should be stationed nearby to ensure good communication. In addition to centralizing the control room, the optimization of human resources and other activities can be considered to achieve production excellence.

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315 KB

Asahi Kasei Synthetic Rubber Singapore Pte. Ltd. - S-SBR Production Automated Using CENTUM VP, ProSafe-RS, PRM, and FOUNDATION™ fieldbus Solutions

  • PRM allows a preventive maintenance approach where maintenance can be scheduled and performed before a field device fails.
  • Exaquantum gathers plant data from the CENTUM VP to generate a variety of reports on the polymerization process.

410 KB

Samsung Fine Chemicals - Fine Chemical Plant Automates All Operations and Reduces Production Losses with Yokogawa's Exapilot

  • Based on a careful review of all operational procedures and operator roles and configured new SOPs in Exapilot.
  • As a result, SFC has been able to reduce operator workload, improve product quality, and reduce production losses.

215 KB

Sinopec Zhongyuan Petrochemical - Stable Operation and Proactive Maintenance Realized at New Coal-chemical Plant in China

  • Stable operation and proactive maintenance were realized at new coal-chemical plant in China.
  • Yokogawa engineers ensured a successful and efficient commissioning and startup.
Industries: Petrochemical

436 KB

PT AMI - Legacy System Replaced with Yokogawa CENTUM VP and ProSafe-RS at PTA plant in Indonesia

  • Legacy System Replaced with Yokogawa CENTUM VP and ProSafe-RS at PTA plant in Indonesia.
  • PID parameters imported to CENTUM VP without complex calculations.
Industries: Base Chemical

223 KB

Map Ta Phut Olefins Company Limited - Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments

  • Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments.
  • The CENTUM VP PCS and ProSafe-RS SIS were integrated using the same engineering environment.
  • Nearly 60 gas chromatographs and a large number of other types of analyzers in several analyzer houses.
Industries: Petrochemical

187 KB

Alexandria Fiber Company - Application of FOUNDATION Fieldbus™ to Acrylic Fiber Production Process at Alexandria Fiber Co. (AFCO)

The AFCO project is a showcase of the good coordination between Yokogawa Middle East, Yokogawa Thailand, Yokogawa Singapore, and Yokogawa Electric Corporation. Yokogawa Middle East and Yokogawa headquarters both were involved in the project execution.


269 KB

SINOPEC SABIC Tianjin Petrochemical Co., Ltd. - Yokogawa Provides CENTUM CS 3000, PRM, and Exaquantum Solutions for China's Largest Refinery/Petrochemical Complex

  • Yokogawa provides CENTUM CS 3000, Exaquantum and PRM solutions for China's largest refinery/petrochemical complex.
  • Process data management by Exaquantum is a key issue in the petrochemical complex.
Industries: Petrochemical

243 KB

PetroChina Dushanzi Refinery and Petrochemical Complex - Yokogawa Provides Control System and Field Instruments for New Refinery and Petrochemical Complex in China

  • Using the CENTUM CS 3000 system, many kinds of plant key performance indexes are calculated and analyzed to produce further improvements.
  • During plant start-up, PRM helps the customer's engineers perform all the loop checks.
Industries: Petrochemical

196 KB

PTT Phenol Company Limited - Yokogawa Provides CENTUM CS 3000, ProSafe-RS, and FOUNDATION™ fieldbus Solutions as Main Instrument Vendor for New Phenol Plant

  • Main instrument vendor (MIV) concept was applied in this project to reduce the total project engineering cost.
  • This consisted DCS, SIS, all instruments, control valves and tank gauging system under working with project management consultant (PMC) and EPC.
Industries: Base Chemical

251 KB

Thai Ethanolamines Co., Ltd. - Integration of CENTUM CS 3000 with ProSafe-RS Improves Plant Safety and Reliability

  • Integration of CENTUM CS 3000 with ProSafe-RS improves plant safety and reliability.
  • Yokogawa's PRM package manages more than 500 HART field devices including control valves.

104 KB

SCG Chemicals - CENTUM CS 3000 Production Control System Contributes to Smooth HDPE Production

  • CENTUM CS 3000 production control system contributes to smooth HDPE production.
  • The challenge for this replacement project was in completing the work and starting up the new CS 3000 system as soon as possible, keeping downtime to a minimum.
Industries: Base Chemical

491 KB

Yunnan Dawei Ammonia Co., Ltd. - CENTUM CS 3000 Efficiently Controls and Monitors Coal Gasification and Air Separation Processes at Ammonia Plant

  • CS 3000 efficiently controls and monitors coal gasification process.
  • Once an operator selects "Start", the necessary instructions are sent to all plant equipment via the sequence control.
Industries: Base Chemical

654 KB

Thai Oleochemicals Co. - Rapid Implementation of Integrated CENTUM CS 3000 and ProSafe-RS Systems at New Oleochemical Plant

  • Rapid Implementation of Integrated CENTUM CS 3000 and ProSafe-RS.
  • The highly reliable CENTUM CS 3000 system has also helped TOL maintain high productivity at this plant.
Industries: Base Chemical

2.9 MB

CYTEC - Migration from Micro-XL and CENTUM CS 1000 to CENTUM CS 3000 Improves Reliability

  • Migration from Micro-XL and CENTUM CS 1000 to CENTUM CS 3000 Improves Reliability.
  • Operations at this plant, which runs more than 330 days per year, are carefully managed by the CENTUM CS 3000 DCS and the CS Batch package.

102 KB

JX Nippon Oil & Energy Corporation - JX Nippon Oil & Energy Corporation Builds Safety Standards-compliant Emergency Shutdown System

  • A certified emergency shutdown system
  • Substantial reduction in maintenance work
  • System configuration with reduced footprint
  • System scalability
Industries: Petrochemical

1.9 MB

Reichhold - High Reliability Assured through Upgrade to Yokogawa's CENTUM CS 3000 Production Control System and CS Batch Package

  • CS Batch is used to automate a wide range of Reichhold's batch processes and multi-product/multi-path processes.
  • Using PRM, process engineers can immediately find out the status of every field device without having to do an onsite inspection.

226 KB

Mitsubishi Chemical Corporation - Mitsubishi Chemical Builds Safer and More Reliable Emergency Shutdown System Using DCS Integration

  • Meet the IEC 61508/JIS C 0508 functional safety standards
  • Proactively introduce leading edge technologies
  • Accommodate the plant licensors' safety, reliability, and maintainability requirements
  • Improve the monitoring and operation functions of the emergency shutdown system
Industries: Petrochemical

507 KB

Samsung Petrochemical Co. Ltd. - Introduction of Exapilot Reduces Workload, Enhances Safety, and Ensures Consistent Product Quality

Samsung Petrochemical Co. Ltd. (SPCL), a major Korean petrochemical company, produces 700,000 tons per year of purified terephthalic acid (PTA) at its Daesan plant. PTA, a white powder substance that is produced by oxidizing and refining para-xylene, is a precursor to polyethylene terephthalate (PET), a polyester material that has excellent thermal resistance and wear resistance and is widely used as a substitute for natural cotton fibers and in film packaging, beverage bottles, tire cords, paints, adhesives, and other applications.

Industries: Petrochemical

260 KB

Asahi Carbon Company Ltd. - Yokogawa Installation of Exaquantum PIMS Package Improves Efficiency of Process Data Management

  • Installation of Exaquantum PIMS package improves efficiency of process data management.
  • Improve quality and yield through proactive maintenance of plant assets.

950 KB

Nitriflex - Introduction of CENTUM CS 3000 Maximizes Productivity and Improves Product Quality at Special Polymer Plant

  • Introduction of CENTUM CS 3000 maximizes productivity and improves product quality at special polymer plant.
  • A major improvement as a result of this project is that butadiene monomer recovery efficiency jumped huge.
Industries: Base Chemical

268 KB

Sapthip Co., Ltd. - Yokogawa CENTUM System Automates Production Processes at Thai Renewable Energy Plant

  • CENTUM CS 3000 distributed control system to control the ethanol plant and it's utility boilers
  • Batch processes that require careful automated control for maximum efficiency and product quality
Industries: Biofuel

1.0 MB

Lucite International - CENTUM VP Batch Replaces Legacy System and Improves Production Efficiency at Acrylic Plant

  • CENTUM VP Batch replaces the legacy system and improves production efficiency in the acrylic plant.
  • CENTUM VP Batch capability can handle the recipe management to Batch report handling and unit management.
Industries: Base Chemical

192 KB

PetroChina Company Limited - PetroChina Dushanzi Petrochemicals Polyethylene Plant System Migration

  • PetroChina Dushanzi Petrochemicals Polyethylene Plant system migration.
  • The revamp included the challenging creation of function design specifications (FDS) as well as FAT and SAT.

413 KB

Hanwha Chemical Corporation - Highly Reliable CENTUM CS 3000 Replaces Legacy System and Automates Batch Plant Operations

  • Highly reliable CENTUM CS 3000 replaces legacy system and automates batch plant operation.
  • Working together, Hanwha Chemical and Yokogawa Korea project personnel completed this work on time and on schedule.

1.4 MB

The University of Sydney - Yokogawa provides STARDOM and FAST/TOOLS for biomass pilot plant

  • Yokogawa provides STARDOM and FAST/TOOLS for biomass pilot plant.
  • FAST/TOOLS is an "all in one" SCADA solution that functionsa a data historian.
Industries: Biofuel

243 KB

Braskem - World's First Large-scale Green Ethylene Plant Uses CENTUM VP, ProSafe-RS, and FOUNDATION™ fieldbus Technology

  • As the main automation contractor (MAC) for this plant construction project, Yokogawa Brazil engineered, installed, and commissioned an integrated control and instrumentation solution
  • Yokogawa Brazil completed the commissioning of these systems ahead of schedule and the production of green polymer was started just one week later
Industries: Biofuel

571 KB

PTT Aromatics and Refining Public Company Limited (PTT AR) - Legacy DCS was Replaced by New Production Control Platform CENTUM VP in Aromatics Plant

  • Implementation of multivariable optimizing controllers and robust quality estimators within a record short period
  • 3% rise expected in CCR feed amount
Industries: Petrochemical

744 KB

Nippon Shokubai - FOUNDATION™ fieldbus Technology Introduced to Realize Predictive and Preventive Maintenance

  • Fieldbus technology introduced to realize predictive and preventive maintenance.
  • ISAE to improve the reliability of diagnosis and parameter setting, utilizing data collected by PRM.

2.0 MB

Kaneka Corporation - Optimization of control strategy helps BTG plant save energy and operate more efficiently

  • Kaneka Corporation has urgently needed to implement countermeasures that would reduce this facility's energy costs.
  • Optimization of control strategy helps BTG plant save energy and operate more efficiently.
Industries: Base Chemical

151 KB

UBE Chemicals(Asia) Public Co. - Yokogawa's CENTUM VP and PRM Improve Efficiency at New Nylon Plant in Thailand

  • Yokogawa's CENTUM VP and PRM improve efficiency at new nylon plant in Thailand.
  • At the plant startup stage, PRM was used together with FieldMate to thoroughly check all loops.

225 KB

Korea Kumho Petrochemical Co., Ltd. - Korean Resin and Rubber Producer Relies on Exaquantum to Ensure the Smooth Running of Its Plants

  • At the company's Ulsan resin plant, six Exaquantum servers were connected to CENTUM CS 3000 and other vendor's systems.
  • KKPC needed to expand its SBC capabilities and improve production efficiency at its plants.

712 KB

Bridgestone (Huizou) Synthetic Rubber Co.,Ltd. - CENTUM CS 3000 and Exaquantum PIMS Improve Production Efficiency at Chinese Synthetic Rubber Plant

  • CENTUM CS 3000 and Exaquantum PIMS improve production efficiency at Chinese synthetic rubber plant.
  • Exaquantum provides data on long-term trends needed to make improvements to plant processes.

527 KB

Safripol (Pty) Ltd. - First STARDOM Controller in South Africa Revitalizes Integrated Compressor Control System

  • Single 'look and feel' operator interface for the DCS and NCS
  • Fast and controllable integration cycle
  • High speed hybrid compressor control solution
  • Reduced OPEX for the compressor operation by replacing old and obsolete PLCs with a modern hybrid control platform
Industries: Base Chemical

220 KB

Evonik Stockhausen GmbH - Increasing Productivity by Means of Partially Automated Start-up and Load Change Procedures

  • Up to 90% of all manual tasks can now be carried out automatically.
  • Increasing productivity by means of partially automated start-up and load change procedures.

117 KB

CNOOC and Shell Petrochemicals Company Ltd. - Future-proof digital petrochemicals complex

  • 16,000 FOUNDATION Fieldbus devices
  • Main Automation Contractor (MAC)
  • DCS anywhere concept integration with site SAP system
  • Long term maintenance contract
  • Sustainable development
Industries: Petrochemical

638 KB

CNOOC and Shell Petrochemicals Company Limited - Yokogawa MAS Controls Product Movement and Distribution at Huge Petrochemical Complex

  • All logistics of raw materials, intermediate products and final products are controlled and managed by MAS.
  • MAS enables Operational Excellence with its seamless interface to enterprise resource planning system.
Industries: Petrochemical

45 KB

Sumitomo Chemical Co. - Complete Automation of Operations Reduces Power Consumption and Operator Workload / Sumitomo Chemical

  • Provided a better way to transfer its manufacturing know-how to the next generation
  • Reduced energy consumption and operator workload by implementing Advanced Process Control (APC) and Advanced Operator Assistance (AOA)
Industries: Base Chemical

276 KB

Japan Polychem Corporation - Improvement of Grade-Change Operation / Japan Polychem Corporation, Kawasaki Factory

  • Implementation of AOA package for improved grade-change operation
  • Dramatically reduced operators' workload and transient products, as well as sharable operation know-how
Industries: Base Chemical

265 KB

Evonik Industries, Marl, Germany - Carefully Planned Modernization of Control Systems Makes Chemical Shipping Terminal Fit for the Future

  • The work was based on a preceisely formulated roadmap with detailed checklists for every control cabinet, process station, and network component.
  • The seamless use of the same HMI for both PCS and SIS, and improved safety and integrity.

190 KB

South Korean Petrochemical Company - Exapilot Automates Naphtha Cracker Decoking and Dryer Regeneration Processes at Large Ethylene Plant

  • Exapilot automates comlex and non-routine decoking process of NCUs.
  • Operator workload has been drastically reduced.
Industries: Petrochemical

78 KB

Nisseki Chemical Texas Inc. - One-day Switchover Turns into Profit Increase / Nisseki Chemical Texas, USA

  • One day switchover
  • Productivity improvement and cost effectiveness achievement
Industries: Petrochemical

197 KB

Taiyo Nippon Sanso Corporation - Maximizing Reliability and Engineering Efficiency of Air Separation Plants with STARDOM Network-based Control System

Taiyo Nippon Sanso Corp. was looking for a system that could be easily adopted to its plant architecture. For the following reasons, Yokogawa's STARDOM system with the FCN autonomous controller and the VDS Web-based SCADA software was selected as their control system for a Water-18O plant and other facilities.


294 KB

Sanyo Kasei (Nantong) Co., Ltd., Nantong, Jiangsu, China - Exapilot-based e-SOP System Provides 24/7/365 Guidance, Improving Both Product Quality and Productivity

  • Exapilot was built up as e-SOP system based on the standard operating procedures and the know-how of experienced operators.
  • e-SOP system improved the quality and productivity in the performance chemical plant in China.

47 KB

Nippon Shokubai Co. - Drastic Reduction in Operator Workloads and Faster Plant Startup and Shutdown / Nippon Shokubai Co., Ltd.

  • Easy-to-understand sequence programs' creation
  • An entire programming system built by operators
  • Operator workloads reduction

761 KB

OCI Nitrogen - Dutch Fertilizer Plant Improves Terminal Operations with Yokogawa Total Automation Solution

As the demand for food is increasing worldwide, fertilizers are playing an essential role in improving agricultural productivity. OCI Nitrogen (hereinafter OCI) is a leading producer of mineral fertilizers and the world's largest producer of melamine, which is used to make adhesives and resins for a wide range of applications, such as furniture panels, laminate flooring, coatings, paints, and plastics.

Tsurumi Soda Co., Ltd. Japan - Exasmoc achieved significant power savings / Tsurumi Soda Co., Ltd.

Tsurumi Soda Corporation,Yokohama,Kanagawa Prefecture, Japan

Industries: Base Chemical

134 KB

Iowa Fertilizer Company, Wever, Iowa, USA - Operator Training Simulator Application Reduces Start-up Time at Iowa Fertilizer Complex

  • IFCo chose Omegaland operator training system to make ready for a flawless and safe plant start-up.
  • Omegaland is contributing to operator training prior to completion of the greenfield fertilizer plant.

423 KB

Evonik Oxeno - Seamless Upgrade and Expansion of Control & Safety Systems at Chemical Plant Introduces New Technologies and Prepares for Growth

Yokogawa CENTUM VP and SIS were selected for the Evonik Oxeno's BTX facility expansion project.
CENTUM provides the operational transparency, and more efficient diagnosis of compressors which are the heart of the facility.

Industries: Base Chemical

272 KB

A chemical company - Control System Cyber Security Service Enables Chemical Plant to Take Preventive Measures to Guard against Cyber-Attacks

Yokogawa's network healthiness check service helped the customer identify what they need to protect against cyber-attacks.
By “visualizing” network traffic in control system, the customer was able to detect unauthorized communication in their system.


361 KB

ISP Marl GmbH - Enhancing Automation Performance Reduces Operator Stress and Enables Safer and More Reliable Plant Operations

  • Yokogawa's operational performance program bench mark service enhanced the automation performance at the chemical plant.
  • Operator stress was dramatically reduced by identifying the causes of excessive manual interventions.
Industries: Base Chemical

376 KB

Air Liquide - Yokogawa’s Reliable Technology and Proven Project Execution Capabilities Key to Success of Air Separation Plant Revamp

  • Yokogawa joined forces with Air Liquide to co-innovate the step-by-step revamping plan based on Air Liquide's specific requirements.
  • Customer was satisfied that Yokogawa was able to deliver its solutions on time and on budget.
Industries: Base Chemical

380 KB

TOK TAIWAN CO., LTD. - Manufacturing Execution System with High Traceability Enables Production of High Quality Photoresist for Semiconductor Applications

  • TOK decided to start local production of high-quality photoresist for semiconductor manufacturing near its customers in Taiwan.
  • The MES with traceability comparable with pharmaceutical manufacturing is one of the factors to win the trust of its customers.

339 KB

Royal Dutch Shell - Shell Scotford Chemicals Benefits from Advanced Process Control Application on Monoethylene Glycol (MEG) Unit

  • The Advanced Process Control application implemented on the Scotford MEG unit helped control the plant with less variation, resulting in maximized TEG production and reductions in overall steam consumption.
  • TEG production increases were greater than originally estimated and the prices for steam and TEG used in the post-implementation study were reduced significantly.
Industries: Petrochemical

358 KB

Mitsubishi Chemical Corporation - Improving Maintenance Efficiency through the Use of Field Digital Technology and an Asset Management System

  • A Japanese petrochemical plant leverages FDT/DTM-compliant intelligent field devices and Yokogawa's PRM asset management system for maintenance efficiency.
  • The customer aims to improve maintenance efficiency further by introducing condition-based maintenance (CBM).
Industries: Petrochemical

351 KB

Royal Dutch Shell - Controls Improvement Program (CIP) Helps Control Shell Deer Park Chemicals Complex

  • Yokogawa assisted in the project implementation by providing design review, calculation modifications, pre-commissioning, training of operators and engineers, commissioning and post implementation review.
  • Shell Global Solutions and Shell Deer Park Management were completely satisfied with the way the project was implemented and with the results achieved.
Industries: Petrochemical

Temperature Control for Seal-heating Parts in Wrapping Machinery

The UT series of temperature controllers is perfect for controlling the heating temperature of sealing parts and the temperature of sealing rolls (pre-heating) in a variety of different wrapping machinery.

Construct a High-Speed Data Acquisition System with Ethernet-Enabled Controllers and PLC

This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).

Input Messages Easily with the Touch Screen

The DXAdvanced Paperless Recorder (hereinafter, the DX) lets you write arbitrary messages on the trend display screen that are useful for writing comments or memos. Moreover, with a combination of the DX touch screen model (DX1000T/2000T) and the custom display function, you can write messages, start/stop recording, and perform a variety of other tasks at the touch of a button.

Easily Adding Messages to Manufacturing Data Using the Touch Panel

In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.


568 KB

Impulse Line Blocking Diagnosis

Operators must receive diagnostic information before a line block leads to a malfunction. Yokogawa provides predictive diagnostics based on trend analysis of the blocking factor, which improves maintenance efficiency and reduces maintenance costs.


870 KB

Measurement in Cogeneration and Captive Power Boiler

Steam is still one of the most popular methods of providing an energy source to a process and its associated operations. The more accurate and reliable measurements that are made, the more informed decisions can be taken that affect costs and product quality.


250 KB

Autolevel

Level transmitter configuration can be very time consuming. DPharp transmitters with advanced software functionality eliminate this time consuming task. With maintenance shops getting smaller, finding equipment that allows us to do more with less becomes a priority.


236 KB

Low Flow Cut-off

One of the most common applications for differential pressure transmitters is flow measurement. DPharp differential pressure transmitters have some unique signal conditioning features to eliminate instability at low flow rates.


369 KB

Flue Gas Desulfurization

Recently, air pollution legislations such as the Clean Air Act to reduce the amount of air pollution are increasing worldwide. The Clean Air Act address numerous air quality problems. One of these problems is acid rain caused by sulfur dioxide and nitrogen oxide emissions from fossil-fueled power plants and other industrial and transportation sources.


318 KB

Oil Heater Average Value Control

The CX1000/CX2000 offers an average value computation function making it ideal for controlling temperature and other fluctuating phenomena. The operating status can be controlled in real time, providing operating cost reductions.


993 KB

Electrolysis Plant Trace H2O (Moisture) Measurement by the TDLS200

If water is present after the dry chlorine tower in brine electrolysis plants, the downstream compressor is corroded or the product quality is deteriorated. The moisture level is measured before and after the compressor to prevent the corrosion of the compressor and the deterioration of quality.


554 KB

Measurement of O2 Concentrations in Vacuum Distillation Column in Petroleum Refining

O2 measurement in hydrocarbon vapor is used for safety monitoring in vacuum distillation columns in petroleum refining. With conventional paramagnetic oxygen analyzers, O2 concentrations are obtained through an extractive sampling system, which conditions the sample prior to being analyzed.

Industries: Petrochemical

160 KB

pH Measurement in Flue Gas Desulfurization Systems That Use Magnesium Hydroxide Slurry

In flue gas desulfurization systems that use magnesium hydroxide (Mg(OH)2) slurry, the consumption of the desulfurization agent (Mg(OH)2) is controlled by using online pH analyzers. A great concern in the pH measurement is heavy staining of the pH electrodes by the Mg(OH)2 slurry. To ensure accurate measurement, frequent cleaning of the electrodes with an acid is required, adding to both maintenance workload and cost.

Industry:Chemical, Power


2.8 MB

Chemical Feed

The ADMAG AXR is the world's first 2-wire magnetic flow meter which employs the unique "Dual Frequency Excitation Method," achieving 0.5% of rate of best-in-class accuracy and excellent stability for process measurement. In addition, the newly developed AXR key technologies," achieves the same level of noise immunity as 4-wire type under the fluid condition change and delivers enough performance to meet the requirement to apply in the control loop.


246 KB

Measurement of Concentration of Supersaturated NaCl Solution in Salt Dissolvers at Electrolysis Plants

Control of sodium chloride (NaCl) concentration at a salt dissolver where solid salt is dissolved in water, is highly important because of the electrolysis efficiency. A conventional way of measuring the concentration of supersaturated NaCl solution had been performed by using non-contact type sensors (e.g., γ-ray density meter) since NaCl, impurities, and precipitates are in the solution.


266 KB

Measuring the Electric Conductivity by use of Clean-in-Place (CIP) System

In the manufacturing process of Pharmaceutical, Chemical and Food & Beverage industries, the cleaning and sterilization of tanks and piping are done with various cleaning solutions, fresh or hot water and steam after manufacturing products. Clean-In-Place (CIP) is the system designed for automatic cleaning and disinfecting.


219 KB

Humidity Measurement in Dyeing and Discharge Processes

There are various methods for continuous fabric dyeing as well as dye fixing. When dye is directly applied, steaming (heat treatment) is required. At present the pad-steam method is widely used for continuous dyeing. To ensure stable product quality, the humidity in the steamer is kept at a constant level. 


285 KB

pH/ORP Measurement for Reverse Osmosis

Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.


283 KB

Maintaining High Quality in Soda Electrolysis by Measuring and Controlling Liquid Density

Caustic soda is an important basic material in the chemical industry and is mainly produced by the electrolysis of soda. In the electrolysis process to make concentrated caustic soda, the DM8 Liquid Density Meter ensures high product quality through accurate measurement of liquid density.


509 KB

Liquid Analyzers for Electrolysis Plants

Process liquid analyzers such as pH meters, conductivity meters, ORP meters, and density meters play an important role at electrolysis plants in the control of concentrations of various process solutions. This requires both precision and stability under harsh conditions that include highly corrosive substances, high temperatures, and many impurities.


340 KB

Automatic Custody Transfer System for Cryogenic Gas by Truck Delivery

Many different types of gases are consumed in industries as varied as chemicals, food & beverages, and medical. These gases are normally delivered in liquid form by trucks and dispensed at the customer site. Although the flow volume of cryogenic liquefied gas is used for billing purposes, it is not easy to accurately measure this because the gas is always at saturation temperatures.


912 KB

Integration of Real-time Utility Monitoring with a DCS

The discharge of improperly treated industrial chemicals and fuel gas can have a major impact on the environment, posing a serious threat to public health. Concurrent with the global growth of manufacturing operations to keep pace with market trends, many countries are taking measures to deal with environmental problems.


4.6 MB

Oxygen Measurement in Vapor Recovery

Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).


268 KB

Optimizing Combustion Control with the TDLS200

Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry. Because the large amount of fuel such as gas or fuel oil which is consumed in these processes, their combustion efficiency directly affects the performance and operational costs of the production facilities.

Boiler Drum Level Control

  • In the YS170 and SLPC, single-element control needs to be configured within the user program.
  • The YS1700, however, offers the primary direct mode so that the user program can switch on and off single-element control by changing a parameter.

Boiler Feedwater Treatment Chemical Injection (or Chemical Dosing)

For safe and efficient operation, the quality of feedwater, steam, and condensate in boiler plants must be controlled and maintained in the most favorable conditions.

Compressor Anti-surge Control

  • Compressor start and stop
    The inlet valve and blow-off valve are controlled efficiently.
  • During steady-state operation
    The inlet valve is controlled to regulate the blow-off flow rate of the compressed air. (Flow control)

Data Acquisition and Monitoring for Film Manufacturing Equipment

Controls temperature in, and acquires data from, various internal components of plastic film manufacturing equipment. An easy to use, high cost-performance data acquisition and monitoring system can be assembled by using Ethernet compatible instruments and DAQWORX package software.

Emergency Interlock System for Petrochemical Plants and Others

  • Emergency interlock circuits for petrochemical plants and other facilities must be independent of the main control system.
  • The YS80 Rack Instrument interfaces not only with field devices and upstream control systems, but also with emergency interlock circuits guarding against process abnormalities.

1.3 MB

Finding Danger where It's Impossible to Look

With industrial and economic development comes increasingly large and advanced power plants and factories. Nevertheless, we find many cases where the original cables, cable tunnels, and other components of the power infrastructure have languished under continuous operation.


1.2 MB

Leak Detection Guarantees Pipeline Safety as Your Business Grows

Risk management is crucial when expanding your business.


917 KB

Cost Effective and Accurate pH Measurement in Limestone-Gypsum Flue Gas Desulfurization Systems

In limestone-gypsum flue gas desulfurization systems, the consumption of a desulfurization agent (lime) is controlled using online pH analyzers.

Achieve Optimal Combustion of Fired Heater Using TDLS to Reduce Environmental Impacts and Increase Manufacturing Efficiency

Fired heaters are used for various processes in oil refining and petrochemical plants.

Industries: Petrochemical

Coal Bunker Temperature Monitoring

  • Temperature monitoring is required to prevent wind-fueled fire hazards.
  • The measuring points are up to 600 meters away from the control room.

613 KB

Wireless Tank Level Measurement

Both bulk and finished inventories are stored in distributed tank farm remote from the site operations. These are difficult to instrument due to the infrastructure cost involved. These are then monitored daily by patrol rounds. While effective, this method does require a large skilled labor force to monitor all of tanks. This can impose an additional risk when the stored medium is of a hazardous nature.

Pressure and Temperature Monitoring at Refinery/Fertilizer Plants

  • Daily manual reading of pressure and temperature gauges with report by phone.
  • The customer wants to change measurement from off-line to on-line.
  • Cabling for wired transmitters in huge plants (up to 300 meters long) is expensive.

Measuring Temperature in a Rotating Furnace

Install a YTMX580 on the side of the rotating furnace that can wirelessly transmit measured values from multiple temperature sensors.

Maturing Drum Temperature Monitoring

  • Temperature is monitored to maintain consistency of the viscous fiber entering the drum.
  • Existing system requires manual temperature readings.
  • Wired temperature measurement is not available because the tank is rotating.

Temperature Monitoring at a Tank Farm

  • Wireless temperature measurement
    Gateway x1, transmitter (YTA) x1, repeater x2 (The 2 repeaters are for redundancy)
  • Extended antenna to circumvent obstacles and improve the radio path for stable measurement (communication was unstable when the height of the antenna was low).

Flow, Pressure, and Temperature Monitoring

ISA100 wireless temperature and pressure transmitters with orifice plates allow:

  • No cabling installations or maintenance.
  • Small amount of hardware and simple equipment implementation means minimizing potential vandalism.

Monitoring of Chemical Reactor

ISA100 Wireless Monitoring  

  • Gateway x1, Temperature Transmitter (YTA) x3, Pressure Transmitter (EJX) x1, Repeater x1

Gateway is installed at control room and 3m height extended antenna is set.

Temperature and Pressure Monitoring at Chemical Plants

  • Temperature Transmitter (YTA) and Pressure Transmitter (EJX) are installed at each monitoring point.
  • Repeater is installed on high position.

Directly Measure Oxygen of Process Gas in 5 Seconds or Fewer. An SIL2 Certified Safe Measurement Solution

In maintaining and managing industrial plants, monitoring waste water pH/ORP is both a legal obligation and an unavoidable necessity for protecting the environment. Monitoring without an attentive eye can lead to severe consequences.


331 KB

Tubeless Tyres Performance Testing

Pressure measurement of tubeless tyres to monitor the air loss is one of the key performance tests in the tyre manufacturing units. Relocation of tyres from one testing rack to the other for various tests and frequent movement of the testing setup for conditional tests to various locations calls for cable free implementation for ease of handling.

Industries: Petrochemical

141 KB

Using Visual MESA to Optimize Refinery Steam Systems

Visual MESA© is a steam system optimization and management computer program that was originally developed at Chevron and now marketed by Nelson & Roseme, Inc. Visual MESA is currently used at refinery and chemical manufacturing sites to optimize the overall site steam system and the parts of the electrical system that economically trade off with the steam system.

This paper will explore significant optimization variables and constraints commonly encountered in refinery steam system optimization, the strategies Visual MESA uses to deal with them.


73 KB

A Highly Successful Holistic Approach to a Plant-Wide Energy Management System

In the course of more than twenty years as an engineer involved directly in utility related projects in a number of industries, I have seen a great variety of energy efficiency projects and programs covering the entire spectrum of efficacy. The Deer Park, Texas, plant of the Rohm and Haas Company has a unique energy management program that has proven to be highly successful. This program has resulted in a 17 percent reduction in energy use on a per pound of product basis, saving 3.25 trillion btus and $15 million each year! This article discusses this program, its history, successes, and the unique characteristics that have contributed to those successes. 


589 KB

Visual MESA Real Time Energy Management System

In general, refineries exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.

Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.


1.4 MB

Real Time Online Energy Management System (RTEMS) Implemented at Saudi Kayan Petrochemical Company

Outline

  • Introduction

  • What is Energy Optimization
  • How does a Real Time Online Energy Management System based on Visual MESA work
  • Calculation Foundation for Key Performance Indicators
  • Visual MESA implementation at Saudi Kayan (A SABIC Affiliate) (SK)
    • Optimization Actionable Items
    • Economic Benefits
    • Relevance of Visual MESA RTEMS for SK's Sustainability Initiative
    • Conclusions
Industries: Petrochemical

237 KB

Application of Predictive Control to a Batch Reactor

The REPSOL company had in mind the improvement of the control on one of their chemical reactors. A feasibility study for the implementation of an Advanced Control technique (Predictive Control for temperature control for chemical Reactors - PCR) for a batch reactor for Polyols production has been performed. The proposed technique PCR is based on a dynamic model of the unit which makes the prediction of the process variables behaviour.


158 KB

Utilities Systems On-Line Optimization and Monitoring: Experiences from the Real World

This paper will not describe just all the features of the software or fully explain on-line optimization technology. The objective of this work is to present some interesting facts and lessons from the experience of implementing a cost based optimization program at thirty oil refineries and petrochemical complexes, around the world, since 1997. This paper will focus on the key optimization variables and constraints in steam system optimization, how they should be handled and how the human and organizational aspects can be addressed. 


166 KB

Customers that Operates Power/Steam Cogeneration Systems with References

Industrial facilities where power and steam is produced (i.e., Cogeneration) exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.

Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.

Visual MESA was successfully applied to many industrial facilities worldwide, several of them operating steam and power generation networks of different complexity and capacity but all with energy cost savings. 


890 KB

Real Time Energy Management Some Case Studies

This paper discusses real industrial examples in which the sitewide utilities system of refinery and petrochemical Sites are optimized with a real time, on line, industrially proven software. Experiences gained during more than 20 years of industrial projects deployed worldwide are commented (Refs. 1 to 10 are related to some recent projects). Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are presented. Specific case studies will be discussed in the paper. 


1.0 MB

Energy Management System Helps Refineries to Reduce Emissions and Energy Costs

Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.

In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.

Process plants use different type of fuels, they often operate cogeneration units, their steam networks consist of several pressure levels, there are different types of energy consumers and there are emission limits to be observed. Import or export of electricity in deregulated markets, which could also be traded off with more or less CO2 and other contaminant gaseous emissions, increase the optimization problem complexity.

Industries: Petrochemical

245 KB

Model-based predictive control increases batch reactor production

After a feasibility study, Repsol YPF decided to apply a model-based predictive controller to a batch reactor producing polyols. The predictive controller for reactors (PCR) is a set of control modules that are designed to face most of the reactor configurations. The important increase of production is a consequence of the better handling of the reactor temperature. Here's a description of the unit and control objectives, methodology, project steps, results and the corresponding benefits.


417 KB

Use of Online Energy System Optimization Models

Big and complex industrial facilities like Refineries and Petrochemicals are becoming increasingly aware that power systems need to be optimally managed because any energy reduction that Operations accomplish in the producing Units could eventually be wasted if the overall power system cost is not properly managed. However, process engineers always attempted to develop some kind of tools, many times spreadsheet based, to improve the way utilities systems were operated. The main drawback of the earlier attempts was the lack of data: engineers spent the whole day at phone or visiting the control rooms to gather information from the Distributed Control System (DCS) data historian, process it at the spreadsheet and produce recommendations that, when ready to be applied, were outdated and not any more applicable. 

Industries: Base Chemical

388 KB

Real Time Co2 and Energy Cost Reductions: Field Experiences in Petrochemical Plants

This paper addresses some of the root causes for issues and discusses the best practices that will help to avoid project failures. Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are discussed. It also presents real industrial examples in which the whole utilities system cost of a production Site (i.e., steam, fuels, boiler feed water and electricity) is optimized with a real time, online, industrially well established software.

Industries: Petrochemical

550 KB

Emissions and Energy: an Integral Approach Using an On-line Energy Management and Optimization Model

Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.
In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.


632 KB

Online real-time optimisation helps identify energy gaps

The energy systems, the steps for the implementation of Visual MESA and several features of the model are described in this article, with a focus on the use of the software for the calculation of energy-related KPIs. The EMS implementation project is discussed and the main conclusions relative to the reduction in operating costs are also presented.


416 KB

Proposal To Speed Up the Implementation of an Abnormal Situation

The aim of this work is to present a proposal for implementation of a support framework for abnormal situation management in the chemical process industry. A main feature of the technology developed is that it takes advantage of existing software packages that are familiar to plant engineers (e.g. Plant Information System) and a commercial process simulator. On the basis of three sources of information (a historical database, a HAZOP analysis, and a first principles plant model), the support framework is developed and easily implemented into the real plant. It consists of a preprocessing module, which performs a variety of key tasks using plant data such as data reconciliation, filtering, and denoising. Some of the outputs of this preprocessing module are the inputs of the fault diagnosis system (FDS). This FDS is a combination of a pattern recognition approach based on neural networks and a fuzzy logic system (FLS) in a block oriented configuration. The case study used to demonstrate the FDS implementation corresponds to a real petrochemical plant.


887 KB

Online Energy and Emissions System Management Helps Refineries and Petrochemicals Minimize Costs

Experiences gained during more than 20 years of industrial projects deployed worldwide are commented. Main project steps are explained and critical details to be taken into account to assure successful use and proper technology transfer are presented. Specific case studies will be discussed in the paper. Open loop vs Closed loop implementation is also presented. 


1.4 MB

Plant Overview: Rohm and Haas Texas Inc.

Rohm and Haas Company is one of the world's largest manufacturers of specialty materials, including adhesives, sealants, coatings, monomers, electronic materials, inorganic and specialty solutions, and ion exchange resins. Founded in 1909 by two German entrepreneurs, Rohm and Haas has grown to approximately $6 billion in annual revenues.


1.1 MB

Alarm Management – the strategy and process of striving for a well-managed operation

Alarm management is not just a project that has a start and end date; it's a continuous cycle. Once the alarm system has been reviewed and improvements have been identified, we must check that controls are in place to ensure the alarm system remains functional. The key is to ensure that the system is continuously monitored and any changes are fully documented. There are seven key steps for alarm management. Rationalization is one of those critical steps.

Industries: Petrochemical

465 KB

Improve Your Distillation Operations Through Procedural Automation

This paper shows how to improve distillation operations by focusing on procedure automation. It will review the importance of using procedures in distillation operations and highlights the collaboration work underway between Fractionation Research Inc. (FRI) and Yokogawa Corporation to improve procedural operations.


620 KB

Real-time Production Organizer: Yokogawa's New Approach to Production Management

The worlds of process automation and production management have been converging for some time. What once used to be islands of automation and production management functionality connected through highly proprietary integration schemes that were costly to maintain have developed into integrated platforms that provide seamless data exchange between the world of automation and the plant floor, the functions of production and operations management, and integration with business level systems.


541 KB

Yokogawa's Modular Procedural Automation is a Knowledge Preservation Tool for the Process Industries

The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.


623 KB

Reducing Lifecycle Costs With the Power of Fieldbus

From engineering to installation, commissioning, operations, and maintenance, FOUNDATION fieldbus offer significant cost reductions of 30 percent or more versus conventional analog systems. Many of these cost reductions come from the advanced functions that fieldbus offers versus analog technology.


1.6 MB

Yokogawa vigilantplantservices: Using Applied Industry Knowledge to Solve Key End User Issues

The automation suppliers that will be successful in the long term will be those that effectively address application or industry specific problems for end users with a value proposition that cannot be ignored. These problems exist throughout the process industries today, and they won't be solved by simply offering a product, but through a combination of hardware, software, services, application expertise, and knowledge.


879 KB

Yokogawa's VigilantPlant Road Map to Operational Excellence

In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action. 


734 KB

Yokogawa Unveils VigilantPlant

Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.


814 KB

Yokogawa VigilantPlant Services Provide a Sustainable Approach to Continuous Plant Improvement

Process automation end users are under more pressure than ever to do more with less. The current economic climate means that many automation capital projects are on hold. With capital budgets tighter than ever, users instead focus on operational budgets (where cost cutting is also a key concern), or on automation investments with a very rapid return on investment.


1.3 MB

Yokogawa VigilantPlant Services Revisited

In today's dynamic industrial marketplace, the only constant is change. Raw material costs, energy costs, market demands, environmental and safety regulations, technology, and even the nature of the labor force itself are constantly changing, and not always in predictable directions.


445 KB
  • Jan 2012
Consolidation of refinery control rooms - Petroleum Technology Quarterly thumbnail

Consolidation of refinery control rooms - Petroleum Technology Quarterly

Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.


299 KB
  • Jul 2011
Automating procedural operations for continuous processes - Petroleum Technology Quarterly thumbnail

Automating procedural operations for continuous processes - Petroleum Technology Quarterly

July 2011

Process plants are run according to operational procedures. These procedures consist of a set of tasks that are executed in a consistent manner to achieve a specific objective, such as starting up, shutting down or transitioning a unit as part of making a product. 


336 KB
  • Sep 2008
Handling complexity - Process Worldwide thumbnail

Handling complexity - Process Worldwide

September 2008

Yokogawa is helping a large chemicals site in China manage product transfer by road, ship and pipeline.


401 KB
  • Mar 2006
All in Hand at Nanhai - Process Worldwide thumbnail

All in Hand at Nanhai - Process Worldwide

March 2006

The new CSPC (CNOOC and Shell Petrochemicals Company Limited) petrochemical complex at Daya Bay in southern China is one of the world's largest process industry projects (see box, Figure 1 and Table). It has a control system to match. Process Worldwide spoke to Johan Veerman, principal instrument and process control engineer at CSPC, about the challenges of managing such a huge job.

Industries: Petrochemical

193 KB
  • Sep 2014
Solvay System Migration Doesn't Miss a Beat thumbnail

Solvay System Migration Doesn't Miss a Beat

The Wyoming Trona Ore Mine and Refinery upgrade from Yokogawa Centum CS3000 to CENTUM VP-R5 involved two domains, 21 RIO and FIO field control stations, 17 operator stations, 6 engineering stations and 8 different plant servers

Industries: Base Chemical

103 KB
  • Apr 2008
A Methodology for Batch Control Implementation - Real World Lessons thumbnail

A Methodology for Batch Control Implementation - Real World Lessons

ISA S88.01 provides great benefit to users and vendors by solidifying batch operating models and standardizing batch control terminology. On the other hand, as befits an industry-wide standard, ISA S88.01 leaves great flexibility for individual users to apply their own project practices and implementation methodology. Even when utilizing ISA S88.01 models and terminology, many pitfalls remain for those who implement batch controls and recipe management without thinking ahead. Real-world project experience has demonstrated a number of design and implementation "lessons" which might be overlooked to the eventual grief of the batch engineer.


93 KB
  • Apr 1999
What Does a Procedure Look Like? The ISA S88.02 Recipe Representation Format thumbnail

What Does a Procedure Look Like? The ISA S88.02 Recipe Representation Format

The S88.02 draft standard defines a means for depicting procedural control in master and control recipes. This depiction method is called a Procedural Function Chart (PFC). This standard depiction is based on the requirements of S88.01, technical report ISA-TR88.0.03-1996, user requirements, previous standards and commonly used procedure depiction methods in use today. PFCs can provide a common basis for the exchange of recipes, reduce the learning curve between control systems, and establish a common ground for improved human communication. This paper provides a brief overview of the development of PFCs, the rules for their use and some of the benefits expected by their adoption in the industry.


282 KB
  • Apr 2000
An Integrated System with Batch functions And Front-End Scheduling based on S88 - Application to Beverage Plant thumbnail

An Integrated System with Batch functions And Front-End Scheduling based on S88 - Application to Beverage Plant

The case study in this paper illustrates the value of integrating front-end scheduling with a batch control system. Recipe changes, and addition of recipes, occur frequently in the target process. However, since both scheduler and batch packages were designed with the ISA-S88.01 model in mind, these packages could be tightly coupled (well integrated) – and, as a result, it is easy to add or change recipes. The front- end scheduler is not limited to performing scheduling; it also provides an easy-to-grasp real-time production status display which can help enhance efficiency and productivity.


171 KB
  • Apr 2001
Automatic Adaptation of Batch Logic to Changing Levels of Field Automation thumbnail

Automatic Adaptation of Batch Logic to Changing Levels of Field Automation

As batch processes are automated, it is common to leave certain less essential field devices without automatic actuators. Thus, the initial control design must accommodate both automated and manual activities. Later, the manual field devices may be automated, either one-at-a-time or in related groups as equipment modules. These field changes, often occurring over a period of years, each require rework of the batch control logic, which can easily exceed the cost of the actuator. In response to this undesirable situation, a technique has been developed which permits the batch design to automatically modify itself, or evolve, to accommodate changes in field automation.


179 KB
  • Apr 2001
Six Sigma and S88 Unite for Batch Automation Productivity Improvement thumbnail

Six Sigma and S88 Unite for Batch Automation Productivity Improvement

Six Sigma is a quality improvement methodology applied to improving any type of process. It is a methodology endorsed by and heavily integrated into several major chemical companies.


92 KB
  • May 2004
Production Performance Ratings thumbnail

Production Performance Ratings

Key Performance Indicators (KPIs) are used in batch processing industries as measurements of production performance. Their use is one element in the current trend of real-time performance management. A single KPI used as the primary measurement of production can cause other dimensions of production performance lose importance. When multiple KPIs are used to measure a batch's production performance it can be difficult to reconcile differences between them for individual batches or for groups of batches. KPIs based upon meeting a target, or specification, measure absolute performance yet do not provide relative information regarding how a batch performed against its peers. The peer comparisons are important for monitoring variability of production performance, which is a critical factor in documenting ROI.


52 KB
  • Oct 1998
Achieving Increased Batch Plant Productivity by the Application of a Multi-Level DCS Solution thumbnail

Achieving Increased Batch Plant Productivity by the Application of a Multi-Level DCS Solution

The application of DCS-based "advanced controls" is a common method of achieving enhanced performance from continuous processes such as refinery units. However, it is less widely recognized, but nonetheless true, that modern DCS systems can include other software tools for the significant improvement of batch plant productivity, product quality, and economic performance. Due to the fundamental processing differences between the two types of plants, unique batch "advanced control" features are required which are different from those used for continuous plants.


393 KB
  • Jan 2013
Promoting Excellence in Process Automation - Control Engineering thumbnail

Promoting Excellence in Process Automation - Control Engineering

CONTROL, January 2013

Standard Automation Methodology Improves Operations and Prevents Incidents by Enabling the Sharing of Best Practices Among Operators.


221 KB
  • Jul 2012
Procedural Automation Helps Reduce Energy Consumption at Commercial-Scale Pilot Plant - ARC Insights thumbnail

Procedural Automation Helps Reduce Energy Consumption at Commercial-Scale Pilot Plant - ARC Insights

ARC believes that by implementing procedural automation, many process plants can minimize variability to help ensure smooth, efficient, and safe state transitions.

Why Yokogawa? Migrating from a Honeywell Platform to Yokogawa's CENTUM VP

Honeywell and Yokogawa have both been producing Distributed Control System (DCS) platforms for decades, and both are very active in this area. In 1975, Honeywell introduced its TDC2000 platform and Yokogawa brought out CENTUM. These two competing systems emerged from a similar place, oil refining and petrochemical industries, so they started out with similar basic concepts and use cases in mind. 

Combustion & Fired Heaters eBook - An Analytical Approach to Improving Safety & Efficiency

In this eBook we explain how to improve fired heaters safety & efficiency by controlling combustion using TDLS technology. Download it now and learn:

  • The 4 top industry challenges related to fired heaters
  • How to efficiently and safely manage combustion
  • How TDLS technology can improve operational excellence in fired heaters
Industries: Petrochemical

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    Understanding Pressure Transmitter Manifold Technology and Selection

    Join this webinar to better understand which manifolds you should use for specific applications and conditions. You will learn:

    • A brief history of manifolds
    • An overview of the different types of manifolds that are available
    • The advantages, disadvantages, and application considerations you should consider when selecting a manifold

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